Three-dimensional printed article

ABSTRACT

A process for forming an absorbent article comprising a substrate having a composite image printed thereon. The composite image includes artwork portions printed on the top and bottom surfaces of the printed article substrate, which are vertically aligned with each other.

FIELD OF THE INVENTION

The present invention generally relates to printed articles for use inconsumer goods such as absorbent articles and, more specifically, to athree-dimensional printed article having a three-dimensional compositeimage printed thereon, wherein the composite image includes imageportions printed on both surfaces of the printed article.

BACKGROUND OF THE INVENTION

Absorbent articles, such as diapers and feminine hygiene products,generally include an absorbent core disposed between a liquid-permeable,body-facing topsheet and a liquid-impermeable, garment-facing backsheet.An additional layer of material is often applied to the garment-facingside of the backsheet as an external cover. The external cover to theabsorbent article can be formed from a non-woven material to provide asoft texture to the absorbent article. The external cover also can formthe landing zone for a mechanical fastener, and can therefore includemechanical fastening elements, such as loops.

The external cover also can include printed images to improve theaesthetic appeal of the absorbent article. A conventional approach toproviding such aesthetic appeal includes printing images on the exterior(garment-facing) surface of the external cover. This method providesgood image resolution, but creates problems with color loss and fuzzvisibility. Colors on the garment-facing surface of the external covercan be lost when they come into frictional contact with other surfaces,such as hands, clothes, complementary mechanical fastening elements(e.g., hooks), etc. This results both in the degradation of the printedimage and the undesirable color transfer of the printed image to thecontacting surface. Colors on the garment-facing surface of the externalcover also increase the apparent degree of fuzz on a fibrous substrate,such as a non-woven web.

An alternate conventional approach intended to limit color loss and fuzzvisibility includes printing images on the interior (body-facing)surface of the external cover. Printed in this manner, the images areonly visible when viewed through the external cover, and they appearmuted, having a reduced image resolution.

Accordingly, it would be desirable to provide a printed article thatcould be used as an external cover for an absorbent article, whichprinted article retains the advantages and reduces the disadvantages ofthe conventional printing methods. Specifically, such a printed articleshould advantageously exhibit good image quality, limited color loss,and a limited degree of fuzz.

SUMMARY OF THE INVENTION

Disclosed herein is a printed article generally including a translucentor transparent substrate. A portion of a composite image is printed onthe top surface of the substrate and a portion of the composite image isprinted on the bottom surface. The resulting printed article exhibitsgood image definition, low color loss and apparent fuzz, and has theunexpected benefit of providing an image with an apparentthree-dimensional character. This printing scheme may be used with awide variety of substrate-ink combinations, and may be integrated intoconventional printing processes.

One aspect of the disclosure provides a printed article including asubstrate having a thickness of about 60 micrometers (μm) or more, and acomposite image. In another embodiment, the substrate may have athickness of about 12 micrometers (μm) or more, and a composite image.

The substrate includes a first surface and a second surface. Thecomposite image has a composite surface area, and includes a firstartwork portion having a first surface area printed on the firstsurface, and a second artwork portion having a second surface areaprinted on the second surface. The first artwork portion and the secondartwork portion are visible when viewed from a vantage point above thefirst surface. In an embodiment, the substrate is a non-woven material.In an alternate embodiment, the substrate may be a polymeric film havinga thickness of about 30 μm or more.

Another aspect of the disclosure provides an absorbent article includinga topsheet having a body-facing surface and a core-facing surface, abacksheet having a garment-facing surface and a core-facing surface, andan absorbent core disposed between the core-facing surface of thetopsheet and the core-facing surface of the backsheet. The absorbentarticle also includes a printed article substrate having a first surfaceand a second surface, the second surface of the printed articlesubstrate being disposed on the garment-facing surface of the backsheet.Furthermore, the absorbent article includes a composite image having acomposite surface area, the composite image including a first artworkportion having a first surface area printed on the first surface and asecond artwork portion having a second surface area printed on eitherthe second surface or the garment-facing surface of the backsheet. Thefirst artwork portion and the second artwork portion are visible whenviewed from a vantage point above the first surface.

Yet another aspect of the disclosure provides a process for forming anabsorbent article, the process including the steps of (a) providing acontinuous-sheet substrate having a thickness of about 60 μm or more,the substrate including a first surface and a second surface; (b)delivering the substrate to a printing apparatus including a firstprinting station and a second printing station; (c) printing a firstartwork portion having a first surface area on the first surface; (d)printing a second artwork portion having a second surface area on thesecond surface; (e) cutting the continuous-sheet substrate formed bysteps (a)-(d) into a plurality of printed articles; and, (f) joiningeach of the plurality of printed articles to an absorbent assembly. Theabsorbent assembly includes a topsheet having a body-facing surface anda core-facing surface, a backsheet having a garment-facing surface and acore-facing surface, and an absorbent core disposed between thecore-facing surface of the topsheet and the core-facing surface of thebacksheet. The first artwork portion and the second artwork portion forma composite image having a composite surface area. Furthermore, thefirst artwork portion and the second artwork portion are visible whenviewed from a vantage point above the first surface. The printed articleis joined to the absorbent assembly on the garment-facing surface of thebacksheet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a cross-sectional view of a three-dimensional printedarticle.

FIG. 1B is a top plan view of the three-dimensional printed article ofFIG. 1A.

FIG. 2A is a top plan view of a composite image on the three-dimensionalprinted article of FIG. 1A.

FIG. 2B is a top plan view of a first artwork portion on thethree-dimensional printed article of FIG. 1A.

FIG. 2C is a top plan view of a second artwork portion on thethree-dimensional printed article of FIG. 1A.

FIG. 3 is a side view of an absorbent assembly including thethree-dimensional printed article of FIG. 1A.

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as thepresent invention, it is believed that the invention will be more fullyunderstood from the following description taken in conjunction with theaccompanying drawings. Some of the figures may have been simplified bythe omission of selected elements for the purpose of more clearlyshowing other elements. Such omissions of elements in some figures arenot necessarily indicative of the presence or absence of particularelements in any of the exemplary embodiments, except as may beexplicitly delineated in the corresponding written description. Thedrawings are not necessarily to scale.

DETAILED DESCRIPTION OF THE INVENTION Definitions

The term “absorbent article” refers to a device that absorbs andcontains liquid, and more specifically, refers to a device that isplaced against or in proximity to the body of the wearer to absorb andcontain the various exudates discharged from the body. Absorbentarticles include items such as diapers, pull-on diapers or pant-typegarments, training pants, incontinence briefs, incontinenceundergarments, absorbent inserts, diaper holders and liners, femininehygiene garments, and the like.

The term “body-facing” is used to describe a surface of an article thatis in contact with or facing the body of a wearer when the article isworn. The term “garment-facing” is used to describe a surface of anarticle that is in contact with or facing a garment being worn when thearticle itself is worn.

The term “disposed” is used to mean that an element(s) is formed (joinedand positioned) in a particular place or position as a unitary structurewith other elements or as a separate element joined to another element.

The term “joined” encompasses configurations whereby an element isdirectly secured to another element by affixing the element directly tothe other element, and configurations whereby an element is indirectlysecured to another element by affixing the element to intermediatemember(s) which, in turn, are affixed to the other element.

“Mechanical fastener” refers to a fastening system or mechanism relyingon physical restraint, magnetic fields, or engagement of portions of thefastener for operation. Examples of mechanical fasteners arehook-and-loop, hook-and-hook, buttons, snaps, tab-and-slot, zippers,magnet(s), and tongue-in-groove fasteners.

The terms “typical adhesive” and “traditional adhesive” areinterchangeable and refer to an adherent which demonstrates adhesionwhen applied to another material generally (i.e., the other material isnot specially selected). Traditional adhesive materials connect to othermaterials indiscriminately and may stick to a variety of materials.

The terms “stretchable” or “elastic” refer to materials which areextensible and which also return to substantially their originaldimensions when the external pulling force is removed. The term“extensible” refers to materials which elongate or increase in at leastone dimension when subject to an external pulling force.

“Color concentration” refers to the fractional surface area of a printedregion that is actually printed with ink. A color concentration of lessthan 1.0 can be used to provide a lighter apparent region color (e.g.,when the underlying substrate is white or clear). A visual blend (or“build”) of two overlaying colors resulting in a third, differentapparent composite color is also possible when the color concentrationof the top overlaying color is less than 1.0. Typical colorconcentrations that are useful when building composite colors include,for example, less than about 0.75, less than about 0.5, and less thanabout 0.25, less than about 0.10, and less than about 0.05.

“Color density” refers to the fraction of incident light reflected froma surface. The color density of a printed surface is unitless and isdetermined as log₁₀(1/R), where R is the fractional reflectance ofincident light from the surface. For example, a printed surface thatreflects 10% of incident light has a fractional reflectance R=0.1 and acolor density of 1.0 (i.e., log₁₀(1/0.1)). Color density and/orreflectance can be measured with a color meter (available, for example,from GretagMacbeth, LLC, New Windsor, N.Y.).

“Visible” refers to an image or color as it appears when viewed from aparticular vantage point, and may be the image or color that resultsfrom the superposition of two overlaying images or colors. Unlessspecified otherwise, the vantage point from which a printed articlesubstrate is viewed is a point displaced above the first (orgarment-facing) surface of the substrate, such that the normal distancefrom the vantage point to the first surface of the substrate is lessthan the normal distance from the vantage point to the second (orbody-facing) surface of the substrate.

The term “spot color” refers to a color applied directly to a substrateby a printing apparatus with a single ink color. A spot color need notbe a primary color. It can represent a single blend of multiple inkcolors, which blend is applied to the substrate as a single color in asingle application step. In contrast, a “process color” is a color thatis formed by the application of two or more color inks to the sameregion of a substrate to form an apparent third color (e.g., applicationof yellow and red colors to build orange). A process color can be formedwith a layered application of two (or more) color inks on the samesurface of the substrate. Within the context of the present disclosure,a process color can also be formed by applying at least one color ink oneach of two opposing, vertically aligned surfaces of the substrate.

Three-Dimensional Printed Article

FIGS. 1A and 1B illustrate a substrate used in a three-dimensionalprinted (3DP) article according to the present disclosure.

FIGS. 1A and 1B show a substrate 100 of a 3DP article 10. FIG. 1A is across-sectional view of the 3DP article 10 taken along line a-a′ shownin FIG. 1B. The substrate 100 is generally planar, and has a firstsurface 200 and a second surface 300 opposing the first surface 200.When integrated into a absorbent article (e.g., a diaper), the firstsurface 200 is generally on the garment-facing side of the absorbentarticle, and the second surface 300 is generally on the body-facing sideof the absorbent article. Thus, any images on the 3DP article 10 shouldbe visible when viewed from the above the first surface 200, for examplefrom a vantage point V as shown in FIG. 1A.

In FIG. 1A, the second surface 300 is illustrated as a generally planar,smooth surface, while the first surface 200 is illustrated as agenerally non-planar, contoured surface. The first surface 200 includesa series of ridges 202 disposed thereon that define a series ofrecessions 204 between the ridges 202. The non-planar contour of thefirst surface 200 can be an intentional design selection for anyarbitrary substrate material, which design selection is intended toenhance the three-dimensional appearance of an image printed on the 3DParticle 10 or to provide an aesthetic pattern (e.g., a quilted surface)on the substrate 100 absent a printed image. In the case of a non-wovensubstrate 100, the recessions 204 can represent bonding sites for thenon-woven material. The second surface 300 is generally selected to besmooth to facilitate attachment of the 3DP article 10 to anotherstructure in a composite article, for example the backsheet of anabsorbent article. In more general embodiments (not shown), either,neither, or both of the first surface 200 and second surface 300 can begenerally smooth or contoured.

The substrate 100 has a thickness 102 that is generally the normaldistance between the first surface 200 and the second surface 300, asshown in FIG. 1A. The thickness 102 includes the contribution of anynon-planar elements of the substrate 100, such that the thickness 102represents the maximum normal distance between two points on the firstsurface 200 and the second surface 300. For example, as shown in FIG.1A, the thickness 102 includes a contribution from the ridges 202 aswell as a contribution from the bulk portion of the substrate 100.

The substrate 100 is generally a translucent material, but also can betransparent. In one embodiment, the substrate 100 itself is not colored;the only color comes from images printed onto the substrate 100. Thus,substrate 100 would generally be white when made from a translucentmaterial, and would generally be colorless and clear when made from atransparent material. However, in an alternate embodiment, the substrate100 may be itself tinted with a colorant, but only to the extent thatthe substrate 100 retains its translucent or transparent character.

FIGS. 2A to 2C illustrate the manner in which a three-dimensionalcomposite image is formed using multiple artwork portions disposed ondifferent locations of the substrate 100.

FIG. 2A shows a composite image 110 that is the visible superposition ofa first artwork portion 210 (shown in FIG. 2B) and a second artworkportion 310 (shown in FIG. 2C). Because of the translucent/transparentcharacter of the substrate 100, both the first artwork portion 210 andthe second artwork portion 310 (and, thus, the composite image 110) arevisible when viewed from above the first surface 200. The compositeimage 110 illustrated in FIG. 2A is a cartoon character; however, thecomposite image 110 can generally include any kind of image such as, forexample, a non-cartoon picture, a colorful pattern of shapes, and/orwords/logos.

The composite image 110 includes several image elements. A compositeoutline element 114 is generally a thin, dark element used to define theouter boundaries of the composite image 110 and to provide contrastbetween different interior regions of the composite image 110. A buildcolor region 116 is a colored region whose visible color is based on acombination of two different colors applied to the first surface 200 andthe second surface 300. An overcolor region 118 is a colored regionwhose visible color is based on a color applied to the first surface200. Similarly, an undercolor region 120 is a colored region whosevisible color is based on a color applied to the second surface 300. Avoid color region 122 is a region with no applied color, having only thecolor of the underlying substrate 100 (which may include a tint). Thecomposite outline element 114 may be black, the build color region 116may be grayish red, the overcolor region 118 may be red, and theundercolor region 120 may be gray. However, these colors are onlyillustrative, and any selection of colors is possible.

FIG. 2B shows the first artwork portion 210 of the composite image 110.The first artwork portion 210 is printed on the first surface 200 of thesubstrate 100. Generally, elements of the first artwork portion 210include those areas or regions where it is desirable to providedefinition and/or vibrant colors to the resulting composite image 110,because the visibility of these elements is not blurred and/or partiallyobscured by the intervening substrate 100 when viewed from above thefirst surface 200. In the embodiment illustrated in FIG. 2B, the firstoutline element 214 is a thin, dark element (e.g., a black line) usedgenerally to define the outer boundaries and interior features of thecomposite image 110. A first build color region 216 is a colored region(e.g., colored red) with a color concentration less than 1. A firstovercolor region 218 is also a colored region (e.g., colored red),generally with a color concentration of about 1, although lower colorconcentrations can be used for lighter image colors. A first undercolorregion 220 and a first void color region 222 have no applied color.

FIG. 2C shows the second artwork portion 310 of the composite image 110.The second artwork portion 310 is printed on the second surface 300 ofthe substrate 100. Generally, colored elements of the second artworkportion 310 include those areas or regions where it is desirable tominimize image deterioration, because the second surface 300 istypically the body-facing surface and, when integrated into a compositeabsorbent article structure, is less subject to image-destructiveevents. In the embodiment illustrated in FIG. 2C, a second build colorregion 316 and a second undercolor region 320 are colored (e.g., coloredgray), generally with a color concentration of about 1, although lowercolor concentrations can be used for lighter image colors. This resultsin a visible color (e.g., grayish red) for the build color region 116that is a mixture of the colors of the first and second build colorregions 216 and 316, respectively (because, for example, a partial redcolor is overlaid on an underlying gray color), and results in anunmixed visible color for the undercolor region 120 (because there is noother color in the first undercolor region 220 atop the secondundercolor region 320). A second overcolor region 318 and a second voidcolor region 322 have no applied color.

The first artwork portion 210 and the second artwork portion 310 can beat least partially vertically aligned, and are generally verticallyaligned such that the colored regions on a surface are coincident withcomplementary regions defined by outline elements on an opposingsurface. Dashed lines 314 of FIG. 2C are provided to indicate thealignment of the first artwork portion 210 and the second artworkportion 310 when superimposed, and the dashed lines 314 are not actuallyprinted on the second surface 300.

However, in some embodiments, the dashed lines of FIG. 2C indicate thelocation of a second outline element 314 that is printed on the secondsurface 300. This duplicate printing of both the first outline element214 and the second outline element 314 can be desirable when imagedeterioration on the first surface 200 is expected during normal use ofthe 3DP article 10; in such cases, the second outline element 314provides definition for the composite image 110 in areas where the firstoutline element 214 may have deteriorated.

The composite image 110 has a composite surface area 112. The compositesurface area 112 includes the visible printed image area of thecomposite image 110, regardless of whether printed on the first surface200, the second surface 300, or both. For example, the composite surfacearea 112 shown in FIG. 2A includes the printed surface area of theoutline element 114 and the colored regions 116, 118, and 120, butexcludes the surface area of void color region 122. Similarly, the firstartwork portion 210 has a first surface area 212 and the second artworkportion 310 has a second surface area 312. These surface areas representthe actual printed areas on the first and second surfaces 200 and 300,respectively. For example, the first surface area 212, shown in FIG. 2B,includes the printed surface area of the first outline element 214, thefirst build color region 216, and the first overcolor region 218.Similarly, the second surface area 312, shown in FIG. 2C, includes theprinted surface area of the second build color region 316 and the secondundercolor region 320.

It is often desirable to select the various printed areas so that themajority of the printed area is on the second surface 300. This is thecase when some deterioration of the composite image 110 is expected, forexample due a loss of ink from the substrate 100 or due to physicaldestruction of a portion of the substrate 100. Such image deteriorationis most likely on the first surface 200 (which is typically thegarment-facing surface in an absorbent article) when abrasion betweenthe first surface 200 and, for example, a garment (i.e., of theabsorbent article wearer) or the floor (e.g., when the absorbent articleis a diaper worn by a baby) can result in a loss of printing ink.Similarly, a portion of the first surface 200 may be the landing zonefor mechanical fastening elements or an adhesive strip; this portion ofthe first surface 200 can be subject to substantial destructionresulting from subsequent fastening and defastening events in thelanding zone. To limit the impact of such deterioration, the ratio offirst surface area 212 to the composite surface area 112 is generallyabout 0.5 or less, about 0.2 or less, or about 0.1 or less, for exampleabout 0.05 or less. With these ratios, more of the composite image 110will remain intact during the useful life of the 3DP article 10 (or anabsorbent article of which it is a part).

Another way to mitigate the effect of image deterioration is tooverprint certain regions of the composite image 110. In such anembodiment, the overcolor region 118, the undercolor region 120, and/orportions thereof can have colors applied to both the first surface 200and the second surface 300. However, the applied colors are the same onboth surfaces. This overprinting of the same color is useful in regionsof the composite image 110 where some degree of image deterioration isexpected because image loss on the first surface 200 reveals theidentical underlying image portion on the second surface 300. When aportion of the composite image 110 is overprinted with duplicate,overlaid images, the ratio of the sum of the first surface area 212 andthe second surface area 312 to the composite surface area 112 is greaterthan 1.0 and is 2.0 or less. When overprinted, this ratio is generallyin a range of about 1.2 to 2.0, for example about 1.5 to 2.0, and can be2.0 when identical images are printed on the first and second surfaces200, 300.

However, it may also be desirable to increase the fraction of theprinted area that is on the first surface 200. Because of the thickness102 of the substrate 100, the contrast between images printed on thefirst surface 200 and those printed on the second surface 300 can createan aesthetically pleasing three-dimensional relief effect. For example,in an alternate embodiment (not shown), the entire cartoon characterillustrated by the composite image 110 is printed on the first surface200, and a background color/pattern (not shown) is printed on a visibleportion of the second surface 300. This provides a visiblethree-dimensional effect in which the cartoon character is displacedaway from the background and therefore appears in the foreground of theimage.

The 3DP article 10 also provides a convenient means to blend twodifferent colors in a printing process (in which the number of availableprinting colors might be limited) to build a visible composite colorthat is different from the two printed colors. As illustrated in FIGS.2A to 2C, the build color region 116 includes the first build colorregion 216 disposed on the first surface 200 that is at least partiallyvertically aligned (or even completely vertically aligned) with thesecond build color region 316 disposed on the second surface 300. Thefirst build color region 216 is printed with a first color and thesecond build color region 316 is printed with a second color. The firstcolor is printed with a color concentration less than 1.0 so that boththe first and second colors are visible and, therefore, blend to formthe composite color when viewed from above the first surface 200.

In general, the top and bottom colors can each either be spot colors orthemselves build colors. For instance, in the illustrated embodiment,first build color region 216 may be red and the second build colorregion 316 may be gray, and these colors can be obtained by printingwith a red spot color as the first color and by printing with a grayspot color as the second color. Alternatively, the first color could bea purple build color formed with a red spot color and a blue spot color.Thus, the final visible composite color in the build color region 116would be grayish purple.

This manner of forming build colors in the composite image 110 isadvantageous because it results in images having a greater resiliency towear. Typical printing inks adhere more strongly to the substrate 100than they do to each other. When the first and second colors are printedon the substrate 100 in the first and second build color regions 216 and316, respectively, the inks are less likely to be removed during thecourse of normal use of the 3DP article 10. When, for example, the firstcolor is printed directly on the substrate 100 and the second color isprinted on the first color, the second color can more easily be lostduring normal use of the 3DP article 10, causing a potentiallyundesirable discoloration.

Forming build colors in the composite image 110 by printing on the firstand second build color regions 216 and 316 can also improve the printvibrancy of the 3DP article 10. Specifically, the build color region 116generally has a color density increase of at least about 0.1 whenmeasured from above the first surface 200. The color density increase isthe color density of the build color region 116 relative to the colordensity of a printed article in which the first and second colors of thefirst and second build color regions are printed on the first surface.The color density increase can also be at least about 0.2, for exampleat least about 0.3.

From the foregoing, it is apparent that the various embodiments providea versatile means to tailor a 3DP article to a variety of applicationsin a way that combines desirable aesthetic image qualities with anincrease in image durability when subjected to normal wear during use.

Three-Dimensional Printed Article Fabrication

The substrate to be printed with an ink composition generally includesmaterials such as a non-woven web, a woven fabric, a polymeric film,combinations thereof, and laminates thereof. A non-woven web is suitablefor a 3DP article intended for use in an absorbent article to provide acloth-like feeling and an aesthetically appealing appearance. Thethickness of the substrate is generally about 60 μm or more and about400 μm or less. Alternatively, the thickness of the substrate is about12 μm or more, about 15 μm or more, about 18 μm or more. When thesubstrate is a fibrous material (e.g., a non-woven web, a woven fabric),the thickness can be in a range of about 80 μm to about 200 μm, forexample about 100 μm to about 200 μm. Alternatively, when the substrateis a fibrous material, the thickness can be about 12 μm or more, about15 μm or more, about 18 μm or more. When the substrate is a polymericfilm material, the thickness can be at least about 30 μm or more, forexample in a range of about 50 μm to about 200 μm, but is generally in arange of about 80 μm to about 200 μm, for example about 100 μm to about200 μm.

The non-woven web and the woven fabric can include natural fibers,synthetic fibers, or a combination of natural and/or synthetic fibers.Suitable natural fibers include wood, cotton, wool, silk, hair, burlap,linen, cellulosic fibers, and combinations thereof. Suitable syntheticfibers include polyolefins (e.g., low density polyethylene, linear lowdensity polyethylene, high density polyethylene, polypropylene),polyamides, polyester, nylon, rayon, and combinations thereof. In wovenfabrics, these polymers can be made into continuous fibers which are, inturn, woven into a fabric. In non-woven webs, the synthetic fibers maybe long, generally continuous fibers such as spunbond and meltblownfibers, or they may be shorter staple-length fibers, such as arecommonly used in carded webs. The fibers may have any shape, such as acircular cross section shape or a non-circular cross section shape. Theresulting non-woven web or woven fabric can be multi-layered, bestretchable, and/or include a mechanical fastening element. The basisweight for the non-woven web or woven fabric is generally in a range ofabout 10 grams per square meter (g/m²) to about 100 g/m², for exampleabout 30 g/m² to about 70 g/m².

In many embodiments, a polyolefin non-woven web is used for reasons suchas cost, processability into the form of fibers, and/or softness in theform of fibers. A suitable non-woven web for use in the 3DP article isavailable from Mitsui Chemical (Japan) under the product codeNWLZ-060111-2. This non-woven web is a polypropylene spunbond withfemale mechanical fastening elements disposed on its surface, has abasis weight of about 45 g/m², and has a thickness of about 100 μm (whenmeasured from its base to the furthest extent of its mechanicalfastening elements).

The polymeric film can be liquid impermeable, liquid permeable, vaporpermeable, vapor impermeable, stretchable, multi-layered, or a laminate(e.g., with a non-woven web). Suitable polymers for the film includepolyolefins such as low density polyethylene, linear low densitypolyethylene, high density polyethylene, polypropylene, and combinationsthereof. Such polyolefin-based polymers may be extruded, cast or blowninto films for subsequent use according to the present invention. Thebasis weight for the polymeric film is generally in a range of about 10g/m² to about 50 g/m².

A wide variety of ink formulations can be used when printing the 3DParticle. Both water- and solvent-based inks can be used with non-wovenwebs, woven fabrics, and polymeric films. Either or both of pigments anddyes can be used as colorants. Pigments are generally used as colorantsbecause they have an increased resistance to water, reducing thepossibility of color loss when the 3DP article is integrated, forexample, into an absorbent article. A corona discharge treatment can beperformed on the substrate to improve transfer and adhesion of the inkcolorant to the substrate (in particular a polyolefin substrate).Adhesion to the substrate can also be improved by usingultraviolet-curing inks, electron beam-curing inks, and/or an adhesiveadditive such as polyvinyl alcohol or ethylene vinyl acetate. Noveltyinks such as disappearing inks and other additives such as detergents,foams, surfactants, and abrasives can also be used. Suitable sources ofprinting inks include Environmental Inks and Coatings (Morganton, N.C.)and Inx International Ink Co. (Schaumburg, Ill.).

Conventional printing methods and equipment such as rotogravure,flexographic, screen printing, and ink jet printing are suitable forprinting the 3DP article. The ink can be applied directly to thesubstrate (e.g., ink jet printing) or the ink can be applied first to atransfer surface such as a printing roll and then to the substrate fromthe transfer surface (e.g., rotogravure, flexographic, or screenprinting). Rotogravure printing uses an engraved print roll and provideshigh quality, high speed, single-color prints. Screen printing issuitable for water-based and hot-melt inks, but it is generally not asfast as, for example, flexographic printing. Ink jet printing issuitable for low-viscosity inks and can be performed at high speeds.

In many embodiments, flexographic printing is used because of thesuitability of the method in printing soft substrates, the speed ofproduction, and cost factors. The flexographic printing process uses araised printing surface made of a flexible material to transfer an inkimage to the substrate. The flexible surface can transfer a good imageeven to a rough substrate surface. The printing can accommodate multiplecolors. Flexographic printing equipment is versatile because it isrelatively easy to change print graphics and the printing plates areless expensive than some of the other equipment types. Suitable liquidinks can be solvent- or water-based, and they dry mainly by evaporation.A wide variety of anilox roll densities and volumes can be used, withsuitable printing equipment using, for example, 360 lines per inch(lpi), 480 lpi, or 600 lpi anilox rolls. A suitable printing press is a12-station UV-flexographic press available under model number FB 2500from Nilpeter USA (Cincinnati, Ohio).

In a process for printing the 3DP article, the substrate is generallyprovided in the form of a continuous sheet. The substrate can have anyof the properties described above (e.g., material composition,thickness, basis weight). In an embodiment, the substrate iscontinuously delivered to a printing apparatus having a first printingstation and a second printing station. The first and second printingstations are used to print the first and second artwork portions (asdescribed above) on the first and second surfaces of the substrate,respectively. As described above, the first and second artwork portionsform a composite image, and both are visible when viewed from above thefirst surface of the substrate. Once the continuous-sheet substrate isprinted with the first and second artwork portions, it is typically cutinto a plurality of individual 3DP articles that can be integrated intoan individual absorbent article.

The first and second printing stations refer to the portions of theprinting apparatus allowing it to print on both sides of the substrate.A typical printing apparatus is capable of printing on only one surfaceof the substrate at a time. In this case, the first and second printingstations are physically located in discrete portions of the printingapparatus (e.g., at different linear distances along the length of theprinting apparatus). The continuous-sheet substrate initially enters thefirst print station where ink is applied to the first substrate surface.While inside the printing apparatus, the continuous-sheet substrate isrotated (e.g., with a turn bar) such that the second substrate surfacefaces the printing mechanism of the printing apparatus. Then, thecontinuous-sheet substrate enters the second print station where ink isapplied to the second substrate surface. Alternatively, the first andsecond printing stations can be physically located in the same portionof the printing apparatus (i.e., at the same linear distance along thelength of the printing apparatus). In this case, ink is applied to bothsides of the substrate simultaneously.

In an alternate embodiment, the first and second print stations can bethe same physical print station in a single printing apparatus. In thiscase, the continuous sheet substrate is registered and fed to theprinting apparatus to print the first artwork portion on the firstsurface of the substrate. Then, the substrate is flipped and re-fed tothe printing apparatus to print the second artwork portion on the secondsurface of the substrate, using the registration mark to ensure that thefirst and second artwork portions are properly aligned.

The first and second printing stations can be used to apply differentcolors in overlapping regions on the first and second surfaces of thesubstrate to form a build color region as described above. An advantageof forming build color regions in this manner is that the number ofcolors can be reduced, thereby increasing process efficiency. The firstand second printing stations (and, therefore, the first and secondartwork portions) each include at least one spot color. The sum of thenumber of spot colors distributed among the first and second printingstations (or, equivalently, the first and second artwork portions) isgenerally not more than about 8, not more than about 6, for example notmore than about 4.

Application—Absorbent Article

FIG. 3 illustrates the use of a 3DP article integrated as a component ofa consumer good such as an absorbent article. Suitable absorbentarticles include diapers (e.g., pants-type, taped), adult incontinenceproducts, feminine hygiene products, and the like. The absorbent articleshown in FIG. 3 includes an absorbent assembly 12 that may constitutethe main structure of the absorbent article with other features added toform the composite absorbent article structure. For example, apants-type diaper would include additional structure to form a waistbandand a taped diaper would include ears with a fastening means (e.g.,mechanical fastener, conventional adhesive, etc.) disposed thereon.

The absorbent assembly 12 includes a liquid pervious topsheet 109, abacksheet 107, and an absorbent core 108, and has the 3DP article 10integrated therein. Alternatively, the 3DP may be printed directly onthe backsheet 107 and/or directly on the topsheet 109. The topsheet 109,the backsheet 107, and the absorbent core 108 may be assembled in avariety of configurations well known in the art. Representativeabsorbent assembly structures are described in U.S. Pat. Nos. 5,899,895and 6,120,487.

The backsheet 107 is generally that portion of the absorbent assembly 12which is disposed adjacent the absorbent core 108 and which prevents theexcreta and/or exudates contained therein from soiling garments or otherarticles possibly contacting the absorbent article, such as bedsheetsand clothing. The backsheet 107 has a garment-facing surface 207 and acore-facing surface 307. In many embodiments, the backsheet 107 may besubstantially impervious to liquid and may include any suitable thinplastic film known in the art, including a breathable film. Suitablebacksheet films include those manufactured by Tredegar Industries, Inc.(Terre Haute, Ind.), and sold under the trade names X15306, X10962, andX10964.

In the illustrated embodiment, the topsheet 109 is disposed adjacent theabsorbent core 108 and may be joined to the absorbent core 108 and/or tothe backsheet 107 by any attachment means known in the art, for exampleas discussed in the '895 and '497 patents mentioned above. The topsheet109 has a body-facing surface 209 and a core-facing surface 309. Thetopsheet 109 is generally compliant, soft-feeling, and non-irritating tothe wearer's skin. At least a portion of the topsheet 109 can be liquidpervious, permitting liquids to readily penetrate through its thickness.A suitable topsheet may be manufactured from a wide range of materialsknown in the art, such as porous foams, reticulated foams, aperturedplastic films, or woven or nonwoven materials of natural fibers such aswood or cotton fibers, or synthetic fibers such as polyester orpolypropylene fibers, or a combination of natural and synthetic fibers.If the topsheet 109 includes fibers, the fibers may be spunbond, carded,wet-laid, meltblown, hydroentangled, or otherwise processed as is knownin the art. One suitable topsheet material is a thermobonded carded webwhich is available as Supplier Code No. P-8 from Fiberweb North America,Inc. (Simpsonville, S.C.).

The absorbent core 108 is disposed between the topsheet 109 and thebacksheet 107, and is adjacent the core-facing surfaces 307 and 309. Theabsorbent core 108 may include any absorbent material which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and otherbodily exudates. The absorbent core 108 may be manufactured in a widevariety of sizes and shapes, for example, rectangular, hourglass,“T”-shaped, asymmetric, etc. The absorbent core 108 may include any of awide variety of liquid-absorbent materials commonly used in disposablediapers and other absorbent articles, such as comminuted wood pulp,which is generally referred to as airfelt, cellulose wadding, meltblownpolymers, chemically stiffened, modified, or cross-linked cellulosicfibers, tissue, absorbent foams including those prepared frompolymerization of a high internal phase emulsion, superabsorbentpolymers, absorbent gelling materials, or any other known absorbentmaterial or combinations of materials. Suitable absorbent corestructures are described in U.S. Pat. Nos. 4,610,678 and 5,260,345.

The 3DP article 10 is integrated into the absorbent assembly 12 byattaching the second surface 300 of the substrate 100 to thegarment-facing surface 207 of the backsheet 107. The 3DP article 10 canhave any combination of the features described above when included inthe absorbent assembly 12. In an alternate embodiment (not shown), theabsorbent assembly 12 can have the same composite structure shown inFIG. 3, with the difference being that the second artwork portion 310(and all of its attendant components) is printed on the garment-facingsurface 207 of the backsheet 107 instead of the second surface 300 ofthe substrate 100. In this case, the resulting composite image 110 isthe same as described above. This alternate embodiment takes advantageof the fact that a printing process step is generally performed for thebacksheet 107 regardless of whether the 3DP article 10 is integratedinto the absorbent assembly 12; therefore, printing the second artworkportion 310 on the backsheet 107 reduces the complexity of the printingprocess for the substrate 100. Alternatively, the 3DP may be printeddirectly on the backsheet 107 and/or directly on the topsheet 109.

The 3DP article 10, the backsheet 107, the absorbent core 108, thetopsheet 109, can be joined to each other or any other element of theabsorbent article by any attachment means known in the art. For example,the attachment means may include a uniform continuous layer of adhesive,a patterned layer of adhesive, or an array of separate lines, spirals,or spots of adhesive. Suitable adhesives include those manufactured byH.B. Fuller Company (St. Paul, Minn.) and marketed as HL-1620 andHL-1358-XZP. Alternately, the attachment means may include heat bonds,pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any othersuitable attachment means or combinations of attachment means known inthe art.

EXAMPLES

For each of Examples 1-3, a composite image is printed onto a continuouspolyolefin non-woven web substrate. The non-woven web substrate is apolypropylene spunbond (45 g/m² basis weight, about 100 μm thickness,available from Mitsui Chemical (Japan)) that is a whitish translucentmaterial. The top (or first) surface of the substrate is contoured,having a soft fabric texture, and includes the loop elements of amechanical fastener thereon. The bottom (or second) surface of thesubstrate is smooth.

The composite image printed on the substrate includes a cartooncharacter, similar to the one shown in FIGS. 2A through 2C, and abackground. The cartoon character has a red body, an orange nose, anddark blue outline elements. The background generally has a colorfulpattern and a word logo as its features, and these features include thecolors yellow, magenta, cyan, and green. The composite image has anapproximate surface area (including the cartoon character and thebackground) of 50 cm² (about 11.4 cm×4.4 cm) and the cartoon characteralone has an approximate surface area of 8 cm² (about 2.5 cm×3.2 cm).

The composite image is printed with a Nilpeter FB-2500 printing press(using 480 lpi anilox rolls and operating at a speed of about 1 m/s;available from Nilpeter USA, (Cincinnati, Ohio)). Six color inks areused: cyan, magenta, yellow, PMS032 red, PMS2745 blue, and PMS3272 green(available from Environmental Inks and Coatings (Morganton, N.C.)). Anorange build color is formed by combining red and yellow.

After printing, the composite image is generally inspected for printquality. Additionally, a tab containing the hook elements of amechanical fastener is affixed to the top surface of the substrate andthen removed. This defastening event damages a portion of the substrate,creating a top surface portion that is relatively fuzzy (i.e., comparedto the substrate in its initial state). After the defastening event, thesubstrate is inspected for image loss and substrate deterioration. Thecomposite image and substrate are viewed from above the top surface ofthe substrate when they are inspected.

Specific details for the printing process and the inspection evaluationare set forth below for each example.

In Example 1, all features of the composite image are formed by printingonto the top surface of the substrate. The colors are bright, there issharp definition between the various features, and the word logo islegible. The composite image, with the cartoon character and thebackground both on the top surface, has a two-dimensional appearance.After the defastening event, the composite image exhibits locationswhere color loss is substantial. The colors that remain on the substrateafter the defastening event accentuate the surface damage causedthereby, making the resulting fuzz more apparent.

In Example 2, all features of the composite image are formed by printingonto the bottom surface of the substrate. The colors and features appearmuted behind the translucent substrate, and the word logo is onlylegible upon close inspection. The composite image, with the cartooncharacter and the background both on the bottom surface, has atwo-dimensional appearance. After the defastening event, the compositeimage exhibits no color loss, and the generation of fuzz is onlyapparent upon close inspection.

In Example 3, the body and outline elements of the cartoon character areprinted on the top surface of the substrate. The background patterns andlogo are printed on the bottom surface of the substrate. The orange noseof the cartoon character is built by printing a red nose on the topsurface of the substrate and by printing a yellow nose on the bottomsurface of the substrate. The composite image is printed on thesubstrate in one printing event (i.e., in a single printing press) inwhich (1) two spot colors (red and blue) are printed on the top surfaceof the substrate in a first print station, (2) a TEFLON-coated turn barinserted into the print line rotates the continuous substrate 180° as ittravels from the first to second print stations, and (3) four colors(cyan, magenta, yellow, and green) are printed on the bottom surface ofthe substrate in a second print station. In the resulting 3DP article,the ratio of the cartoon character surface area (i.e., that portion onthe top surface) to the composite image surface area is about 0.16.

In the resulting 3DP article of Example 3, the colors of the cartooncharacter are bright, and the outline elements provide sharp definitionof its features. The background colors are muted behind the translucentsubstrate, and the resulting contrast between the cartoon character andbackground creates a three-dimensional effect in which the cartooncharacter appears to be in the image foreground. The word logo in thebackground is only legible upon close inspection. The defastening eventis applied to a local region of the composite image where there are someoutline elements on the top surface of the substrate, but the majorityof the region's surface area includes background features printed on thebottom surface. While some color loss is evident from the outlineelements, the low relative surface area of the outline elements resultsin minimal image loss and minimal apparent fuzz.

The creation of the orange build color in Example 3 illustrates theprocess efficiency benefit of forming a build color region in a 3DParticle by printing on opposing surfaces of the substrate. Each ofExamples 1-3 uses six colors. If the orange nose of the cartooncharacter were built by printing on both the top and bottom surfaces ofthe substrate, a total of seven colors would be required for Example 3.For example, the orange nose could be printed with the addition of anorange spot color in the first print station, for a total of threecolors in the first portion of the press (i.e., red, blue, and orange)and a total of seven process colors in the complete printing process(i.e., adding cyan, magenta, yellow, and green in the second printstation). Alternatively, the orange nose could be built with red andyellow spot colors both applied to the top surface of the substrate inthe first part of the press. However, this still would require anadditional process color (i.e., red, blue, and yellow in the first partof the press; cyan, magenta, yellow, and green in the second part of thepress).

The creation of the orange build color in Example 3 also illustrates theincreased print vibrancy of a 3DP article. When measured with aGretagMacbeth color meter (New Windsor, N.Y.) from above the top surfaceof the substrate, the orange nose of the cartoon character from Example1 has a color density of 0.1. The orange nose of the cartoon characterfrom Example 3 similarly measured has a color density of 0.41, thusexhibiting a color density increase of 0.31.

These examples illustrate the ability of a 3DP article to providepleasing aesthetic features with an increased image resiliency whilemaintaining process efficiency.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A process for forming an absorbent article,comprising: (a) providing a continuous-sheet substrate, the substratebeing a non-woven web or a woven fabric, and comprising a first surfaceand a second surface opposing the first surface; (b) delivering thesubstrate to a printing apparatus comprising a first printing stationand a second printing station; (c) printing in the first printingstation a first artwork portion having a first surface area on the firstsurface, the first artwork portion comprising a first outline element;(d) printing in the second printing station a second artwork portionhaving a second surface area on the second surface, the second artworkportion comprising a colored region; (e) cutting the continuous-sheetsubstrate formed by steps (a)-(d) into a plurality of printed articles;and, (f) joining each of the plurality of printed articles to anabsorbent assembly comprising a topsheet having a body-facing surfaceand a core-facing surface, a backsheet having a garment-facing surfaceand a core-facing surface, and an absorbent core disposed between thecore-facing surface of the topsheet and the core-facing surface of thebacksheet; wherein: (i) the first artwork portion and the second artworkportion form a composite image having a composite surface area, thecomposite image comprising a first artwork portion having a firstsurface area printed with an ink composition on the first surface of thesubstrate and a second artwork portion having a second surface areaprinted with an ink composition on the second surface of the substrate;(ii) the first artwork portion and the second artwork portion arevisible when viewed from above the first surface; (iii) the first andsecond artwork portions are vertically aligned such that the coloredregion of the second artwork portion is coincident with complementaryregions of the outline element of the first artwork portion such thatthe first and second artwork portions are printed on the same positionof the substrate and do not occupy different positions at any points inorder to form the composite image; and (iv) the printed article isjoined to the absorbent assembly on the garment-facing surface of thebacksheet, the second surface of the printed article substrate beingdisposed on the garment-facing surface of the backsheet.
 2. The processof claim 1, wherein the substrate is a non-woven web.
 3. The process ofclaim 2, wherein the substrate is a synthetic non-woven web.
 4. Theprocess of claim 3, wherein the thickness of the substrate is about 12μm or more.
 5. The process of claim 4, wherein the thickness of thesubstrate is about 60 μm or more.
 6. The process of claim 1, wherein thethickness of the substrate is about 12 μm or more.
 7. The process ofclaim 6, wherein the thickness of the substrate is about 60 μm or more.8. The process of claim 1, wherein the thickness of the substrate isabout 400 μm or less.
 9. The process of claim 1, wherein the thicknessof the substrate is from about 80 μm to about 200 μm.
 10. The process ofclaim 1, wherein the substrate is a woven fabric.
 11. The process ofclaim 1, wherein the second artwork portion further comprises a secondoutline element.
 12. The process of claim 1, wherein the ratio of thefirst surface area to the composite surface area is about 0.2 or less.13. The printed article of claim 12, wherein the ratio is about 0.1 orless.
 14. The process of claim 1, wherein the ratio of the sum of thefirst surface area and the second surface area to the composite surfacearea is in a range of greater than 1.0 to 2.0.
 15. The printed articleof claim 14, wherein the ratio is in a range of about 1.2 to 2.0. 16.The process of claim 1, wherein the first surface of the printed articlesubstrate includes a series of ridges and a series of recessions betweenthe ridges.
 17. The process of claim 1, wherein an ink composition is awater-based ink.
 18. The process of claim 1, wherein an ink compositionis a solvent based ink.
 19. The process of claim 1, wherein an inkcomposition is a disappearing ink.
 20. The process of claim 1, whereinthe first artwork portion and the second artwork portion comprise thesame ink composition.
 21. The process of claim 1, wherein the firstartwork portion and the second artwork portion comprise different inkcompositions.
 22. The process of claim 1, wherein the printing apparatusis capable of printing only on one surface of the substrate at a time.23. The process of claim 1, the first surface further comprising a firstprocess color region and the second surface further comprising a secondprocess color region, wherein: (i) the first process color region andthe second process color region are at least partially aligned; and,(ii) the step of printing a first artwork portion further comprisesprinting a first color on the first process color region and the step ofprinting a second artwork portion further comprises printing a secondcolor on the second process color region, thereby forming a visiblecolor in the first process color region that is different from both thefirst color and the second color.
 24. The process of claim 1, wherein:(i) the first printing station comprises at least one first spot color;(ii) the second printing station comprises at least one second spotcolor; and, (iii) the sum of the number of first spot colors and thenumber of second spot colors is not more than
 8. 25. The process ofclaim 24, wherein the sum is not more than
 6. 26. The process of claim25, wherein the sum is not more than
 4. 27. An absorbent article formedaccording to the process of claim
 1. 28. A process for forming anabsorbent article, comprising: (a) providing a continuous-sheetsubstrate, the substrate being a non-woven web or a woven fabric, andcomprising a first surface and a second surface opposing the firstsurface; (b) delivering the substrate to a printing apparatus comprisinga first printing station; (c) printing in the first printing station afirst artwork portion having a first surface area on the first surface,the first artwork portion comprising a first outline element; (d)cutting the continuous-sheet substrate formed by steps (a) to (c) into aplurality of printed articles; and (e) joining each of the plurality ofprinted articles to an absorbent assembly comprising a topsheet having abody-facing surface and a core-facing surface, a backsheet having agarment-facing surface and a core-facing surface, the backsheetcomprising a second artwork portion having a second surface area andhaving a colored region, and an absorbent core disposed between thecore-facing surface of the topsheet and the core-facing surface of thebacksheet; wherein: (i) the first artwork portion and the second artworkportion form a composite image having a composite surface area, thecomposite image comprising a first artwork portion having a firstsurface area printed with an ink composition on the first surface of thesubstrate and a second artwork portion having a second surface areaprinted with an ink composition on the garment-facing surface of thebacksheet; (ii) the first artwork portion and the second artwork portionare visible when viewed from above the first surface; (iii) the firstand second artwork portions are vertically aligned such that the coloredregion of the second artwork portion is coincident with complementaryregions of the outline element of the first artwork portion such thatthe first and second artwork portions are printed on the same positionof the substrate and do not occupy different positions at any points inorder to form the composite image; and (iv) the printed article isjoined to the absorbent assembly on the garment-facing surface of thebacksheet, the second surface of the printed article substrate beingdisposed on the garment-facing surface of the backsheet.